Hydration apparatus and method

ABSTRACT

Vessels including an enclosure having an outer perimeter and an interior space, a channel disposed in the interior space, a first port disposed on a surface of the first enclosure at or proximate to a first end of the channel, and a second port disposed on a surface of the first enclosure at or proximate to a second end of the channel, where the channel has a length greater than the shortest distance between the first port and the second port, and where the first port and the second port are in fluid communication with one another. In some cases, the length of the channel is greater than a length of the outer perimeter. Optionally, the vessel may have a second enclosure having an outer perimeter and an interior space with a second channel disposed in the interior space, a third port disposed on a surface of the second enclosure at or proximate to a first end of the second channel, and a fourth port disposed on a surface of the second enclosure at or proximate to a second end of the second channel, where the second port, the third port and fourth port are in fluid communication. In yet some other optional variations, the vessel further includes a plurality of enclosures each having an outer perimeter and an interior space, a channel disposed in the interior space, a port disposed on a surface of the enclosure at or proximate to a first end of the channel, and a port disposed on a surface of the enclosure at or proximate to a second end of the channel, where the channel has a length greater than a shortest distance between the ports, and the second port and the ports disposed on the surface of the plurality of enclosures are in fluid communication. The perimeter shape of the enclosure(s) may be any suitable shape, including, but not limited to, substantially circular, ovate or rectangular.

FIELD

The disclosure generally relates to the preparation of subterraneanformation treatment fluids, and more particularly, but not by way oflimitation, apparatus and methods for preparing treatment fluids from amixture including, in some cases, a hydratable material and water.

BACKGROUND

The statements in this section merely provide background informationrelated to the disclosure and may not constitute prior art.

In the oil and gas drilling and production industry, viscous aqueousfluids are commonly used in treating subterranean wells, as well ascarrier fluids. Such fluids may be used as fracturing fluids, acidizingfluids, and high-density completion fluids. In an operation known aswell fracturing, such fluids are used to initiate and propagateunderground fractures for increasing petroleum productivity.

Viscous fluids, such as gels, are typically an aqueous solution of apolymer material. A common continuous method used to prepare viscousfluids at a wellbore site, involves the use of initial slurry of thepolymer material in a hydrocarbon carrier fluid (i.e. diesel fluid)which facilitates the polymer dispersion and slurry mixing. Althoughthis process achieves the required gel quality, the presence ofhydrocarbon fluids is often objected to in particular fields, eventhough the hydrocarbon represents a relatively small amount of the totalfracturing gel once mixed with water. Also, there are environmentalproblems associated with the clean-up and disposal of bothhydrocarbon-based concentrates and well treatment gels containinghydrocarbons; as well as with the clean-up of the tanks, piping, andother handling equipment which have been contaminated by thehydrocarbon-based gel.

Other applications used for the continuous mixing of viscous treatmentgels include gelling the polymer in a hydrocarbon carrier that is mixedwith water to produce the fracturing gel which is then flowed throughbaffled tanks providing first-in/first-out (FIFO) flow pattern, andallowing for the hydration time of the gel. Yet another technique formixing of dry polymer directly to produce viscous treatment gels isdescribed in Allen, U.S. Pat. No. 5,426,137, Allen, U.S. Pat. No.5,382,411, and Harms et al., U.S. Pat. No. 5,190,374. These techniques,while potentially effective, require several complicated steps toprepare the gel, which presents drawbacks in an oilwell setting.Further, U.S. Patent Application 2004/0256106 A1 discloses an apparatuswithout an eductor, for substantially hydrating a gel particulate usinga mixer in conjunction with an impeller located within the mixerhousing, which prevents formation of gel balls.

Other techniques and equipment useful for the continuous mixing ofviscous treatment gels without utilizing a hydratable polymer in ahydrocarbon are described in Pessin et al., U.S. Pat. No. 7,866,881,which discloses preparation of a viscous treatment gel from dry polymerutilizing a constant volume educator and mixing chimney, where theeductor operates at a constant water rate and pressure thus producing aconcentrated polymer slurry. While effective in preparing an aqueousslurry from dry hydratable polymer and water, there still exists need tofurther minimize equipment size, space requirements, and efficiency.

Some hydration tanks configured in a first-in/first-out configurationare vented tanks which operate by use of gravity to flow a hydratinggel, formed of a polymeric viscosifier in aqueous solution, through thetank. As the polymer concentration in the gel increases, viscosityincreases, and gravity flow of the gel is only possible up to apractical polymer concentration. As a result such systems are not usefulto handle hydration of gels having a high concentration of viscosifier.

Therefore, there is a need for apparatus and methods useful forhydrating constituents at high concentrations to prepare viscoustreatment gels in a continuous mode, without the use of hydrocarboncarriers, and with decreased equipment size and space requirements, suchneed met, at least in part, by the following disclosure.

SUMMARY

In a first aspect, an apparatus is disclosed which includes a firstenclosure having an outer perimeter and an interior space definedtherein, the first enclosure having a first continuous channel in theinterior space, the first continuous channel having a channel-lengthgreater than a length of the outer perimeter of the first enclosure, afirst port disposed on the perimeter of the first enclosure incommunication with a first end of the first continuous channel, and asecond port disposed on a surface of the first enclosure incommunication with a second end of the first continuous channel. Theapparatus also includes a second enclosure having an outer perimeter andan interior space defined therein, the second enclosure having a secondcontinuous channel in the interior space where the channel-length isgreater than a length of the outer perimeter of the second enclosure, athird port disposed on a surface of the second enclosure incommunication with a first end of the second continuous channel, and afourth port disposed on the perimeter of the second enclosure incommunication with a second end of the second continuous channel. Thesecond port and the third port are in fluid communication.

The apparatus may further include a pair of intermediate enclosuresdisposed between the first enclosure and the second enclosure, the pairof intermediate enclosures having a first intermediate enclosure havingan outer perimeter and an interior space defined therein, the firstintermediate enclosure including a continuous channel in the interiorspace having a channel-length greater than a length of the outerperimeter of the first intermediate enclosure, a port disposed on asurface of the first intermediate enclosure in communication with afirst end of the continuous channel, and a port disposed on a surface ofthe first intermediate enclosure and located proximate the outerperimeter, the port in communication with a second end of the continuouschannel. The apparatus may further include a second intermediateenclosure having an outer perimeter and an interior space definedtherein, where the second intermediate enclosure has a continuouschannel in the interior space having a channel-length greater than alength of the outer perimeter of the second intermediate enclosure, aport disposed on a surface of the second intermediate enclosure andlocated proximate the outer perimeter, the port in communication with afirst end of the continuous channel and connected to the port disposedon the first intermediate enclosure in communication with the second endof the continuous channel of the first intermediate enclosure, and aport disposed on a surface of the second intermediate enclosure andlocated proximate the outer perimeter, the port in communication with asecond end of the continuous channel. The first enclosure, the secondenclosure, the first intermediate enclosure and the second intermediateenclosure may be substantially circular, rectangular, oval, triangular,or any suitable outer perimeter shape, and the continuous channels ofthe first enclosure, the second enclosure, the first intermediateenclosure and the second intermediate enclosure may be orientated in aspiral configuration. In some instances, a first fluid flowpath is in aprogressively inward direction through the continuous channels of thefirst enclosure and the second intermediate enclosure, and a secondfluid flowpath is in a progressively outward direction through thecontinuous channels of the second enclosure and the first intermediateenclosure.

Alternatively, the apparatus may include a third continuous channel inthe interior space having a channel-length greater than the length ofthe outer perimeter of the first enclosure, with a first end of thethird continuous channel disposed at or proximate to a port, and a fifthport disposed at or proximate to a second end of the third continuouschannel. The second port, the third port, and the fifth port are influid communication. The first enclosure may further have at least onepair of continuous channels in the interior space, the pair ofcontinuous channels including a fourth continuous channel having achannel-length greater than a length of the outer perimeter of the firstenclosure, a first end at or proximate to a port, and a sixth portdisposed at or proximate to a second end. In addition, the apparatus mayinclude a fifth continuous channel having a channel-length greater thana length of the outer perimeter of the first enclosure, a first end ator proximate to the sixth port, and a seventh port disposed at orproximate to a second end. The second port, the third port, the fifthport, the sixth port and the seventh port are in fluid communication. Insome cases, the first enclosure further includes two pair of continuouschannels in the interior space.

In another aspect of the disclosure, hydration vessels are disclosed,which include an inlet chamber having an outer perimeter and a firstfluid passageway formed therein, where the length of the first fluidpassageway is greater than a length of the outer perimeter and whereinthe first fluid passageway is inwardly or outwardly spiraling, adischarge chamber having an outer perimeter and a second fluidpassageway formed therein, wherein the length of the second fluidpassageway is greater than a length of the outer perimeter and whereinthe second fluid passageway is inwardly or outwardly spiraling. In someaspects, at least one intermediate chamber may be disposed between theinlet chamber and the discharge chamber. The first fluid passageway andthe second fluid passageway are in fluid communication. The outerperimeter shape of the chambers may be substantially circular,rectangular, ovate, triangular, or any other suitable shape.

In some cases the at least one intermediate chamber of the hydrationvessel is a pair of intermediate chambers, where the first intermediatechamber includes an outer perimeter and a first intermediate fluidpassageway therein, and where the length of the first intermediate fluidpassageway is greater than a length of the outer perimeter and isoutwardly spiraling. The second intermediate chamber has an outerperimeter and a second intermediate fluid passageway therein, the lengthof the second intermediate fluid passageway greater than a length of theouter perimeter, and the second fluid passageway is inwardly spiraling.

In some other cases, the inlet chamber, the discharge chamber, and atleast one intermediate chamber of the hydration vessel each include afirst and a second continuous channel, where the continuous channels arepartitioned by a plate having a hole therein, and where the first andthe second continuous channel are in fluid communication. A first fluidflowpath within each chamber is in a progressively inward directionthrough the first continuous channel, and a second fluid flowpath is ina progressively outward direction through the second continuous channel.The first and second continuous channels may be orientated in asubstantially spiral configuration.

Alternatively, the inlet chamber of the apparatus may include a thirdfluid passageway formed therein, where the length of the third fluidpassageway is outwardly spiraling and greater than the length of theouter perimeter, and the first fluid passageway, the second fluidpassageway and the third fluid passageway are in fluid communication. Insome aspects, the inlet chamber may further have at least one pair offluid passageways in the interior space, where the pair fluidpassageways have a fourth fluid passageway, inwardly spiraling, having achannel-length greater than a length of the outer perimeter, and a fifthoutwardly spiraling fluid passageway having a channel-length greaterthan a length of the outer perimeter, where the first fluid passageway,the second fluid passageway, the third fluid passageway, the fourthfluid passageway and the fifth fluid passageway are in fluidcommunication. In some cases, the inlet chamber includes two such pairof fluid passageways in the interior space.

In yet another aspect of the disclosure, a hydration vessel includes afirst outer chamber including an inlet port, a second outer chamberincluding a discharge port, and at least one intermediate chamberincluding a first port and a second port, where the at least oneintermediate chamber is disposed between the first outer chamber and thesecond outer chamber. The first outer chamber, the second outer chamber,and at least one intermediate chamber each have a perimeter and containat least one continuous channel therein, and each continuous channel hasa length greater than the length of the respective chamber perimeter,and each continuous channel is disposed substantially parallel with eachof the perimeters. The inlet port, the discharge port, and thecontinuous channels are in fluid communication. The chambers may besubstantially circular, rectangular, ovate or triangular in outerperimeter shape.

In some embodiments, the first outer chamber, the second outer chamber,and the at least one intermediate chamber of the hydration vessel eachhave a first and a second continuous channel disposed therein, where thecontinuous channels are portioned by a plate having a hole therein, andthe first and the second continuous channel are in fluid communication.A first fluid flowpath is in a progressively inward direction throughthe first continuous channel, and a second fluid flowpath is in aprogressively outward direction through the second continuous channel.The first and second continuous channels may be orientated in asubstantially spiral configuration in some cases.

In some other embodiments, the at least one intermediate chamber of thehydration vessel is a pair of intermediate chambers. Each intermediatechamber contains one continuous channel therein. Fluid flowpaths withinthe continuous channels of the intermediate chambers may alternate in anoutwardly spiraling/inwardly spiraling fashion as mixtures travelthrough the sequence of pair(s) of intermediate chambers.

Alternatively, the hydration vessel further includes a pair ofintermediate chambers disposed between the first outer chamber and theat least one intermediate chamber, where each intermediate chamber ofthe pair of intermediate chambers has a perimeter and contain at leastone continuous channel therein. Each continuous channel has a lengthgreater than a length of the perimeter, each continuous channel isdisposed substantially parallel with each of the perimeters, and theinlet port, the discharge port, and the continuous channels are in fluidcommunication. In some aspects, the hydration vessel also has a secondpair of intermediate chambers disposed between the pair of intermediatechambers and the second outer chamber, where each intermediate chamberof the second pair of intermediate chambers has a perimeter and containsat least one continuous channel therein; each continuous channel has alength greater than a length of the perimeter, and each continuouschannel is disposed substantially parallel with each of the perimeters;and the inlet port, the discharge port, and the continuous channels arein fluid communication. In yet another aspect, a third pair ofintermediate chambers is disposed between the second pair ofintermediate chambers and the second outer chamber, each intermediatechamber of the third pair of intermediate chambers has a perimeter andcontains at least one continuous channel, each continuous channel has alength greater than a length of the perimeter, each continuous channelis disposed substantially parallel with each of the perimeters, and theinlet port, the discharge port, and the continuous channels are in fluidcommunication.

Another aspect of the disclosure is a method for treating at least aportion of a subterranean formation penetrated by a wellbore, the methodincluding introducing into at least one hydration vessel a mixture of aliquid component containing water, a solid component containing ahydratable material, then passing the mixture through the at least onehydration vessel in a continuous manner to form a slurry. A treatmentfluid is then prepared which includes the slurry and an optionalinsoluble particle, and the fluid introduced into the wellbore to treatthe subterranean formation. The hydration vessel includes an inletchamber an inwardly spiraling first fluid passageway, and a dischargechamber having an outwardly spiraling second fluid passageway. In someembodiments, at least one intermediate chamber may be disposed betweenthe inlet chamber and the discharge chamber.

In some embodiments where there is at least one intermediate chamber,the at least one intermediate chamber is a pair of intermediatechambers, where a first intermediate chamber of the pair has anoutwardly spiraling first intermediate fluid passageway, the secondintermediate chamber of the pair has an inwardly spiraling secondintermediate fluid passageway formed therein, and the first fluidpassageway, the second fluid passageway, the first intermediate fluidpassageway and the second intermediate fluid passageway are in fluidcommunication. In some other embodiments, the at least one intermediatechamber includes a first and a second continuous channel, where thecontinuous channels are partitioned by a plate having a hole therein,and the first and the second continuous channel are in fluidcommunication. Further, the first outer chamber and the second outerchamber may each have a first and a second continuous channel, thecontinuous channels are partitioned by a plate having a hole therein,and the first and the second continuous channels are in fluidcommunication. A first fluid flowpath may be in a progressively inwarddirection through the first continuous channels, and a second fluidflowpath may be in a progressively outward direction through the secondcontinuous channels.

In some aspects, the disclosure also relates to a vessel(s) including anenclosure having an outer perimeter and an interior space, a channeldisposed in the interior space, a first port disposed on a surface ofthe first enclosure at or proximate to a first end of the channel, and asecond port disposed on a surface of the first enclosure at or proximateto a second end of the channel, where the channel has a length greaterthan the shortest distance between the first port and the second port,and where the first port and the second port are in fluid communicationwith one another. In some cases, the length of the channel is greaterthan a length of the outer perimeter. Optionally, the vessel may have asecond enclosure having an outer perimeter and an interior space with asecond channel disposed in the interior space, a third port disposed ona surface of the second enclosure at or proximate to a first end of thesecond channel, and a fourth port disposed on a surface of the secondenclosure at or proximate to a second end of the second channel, wherethe second port, the third port and fourth port are in fluidcommunication. In yet some other optional variations, the vessel furtherincludes a plurality of enclosures each having an outer perimeter and aninterior space, a channel disposed in the interior space, a portdisposed on a surface of the enclosure at or proximate to a first end ofthe channel, and a port disposed on a surface of the enclosure at orproximate to a second end of the channel, where the channel has a lengthgreater than a shortest distance between the ports, and the second portand the ports disposed on the surface of the plurality of enclosures arein fluid communication. The perimeter shape of the enclosure(s) may beany suitable shape, including, but not limited to, substantiallycircular, ovate or rectangular. Additionally, the vessels may furtherinclude one or more static mixing elements disposed within the channelto introduce mixing at specific intervals or stages of chemicalreaction.

Methods for treating at least a portion of a subterranean formationpenetrated by a wellbore are also provided, which include introducinginto one or more reaction vessels a mixture of a liquid componentcontaining a first chemical reactant, and a second chemical reactant,and the mixture is passed through the at least one reaction vessel. Atreatment fluid is then prepared and contains the mixture and anoptional insoluble particle, and is subsequently introduced into awellbore. The reaction vessel has a first enclosure having an outerperimeter and an interior space defined therein, a channel disposed inthe interior space, a first port disposed on a surface of the firstenclosure at or proximate to a first end of the channel, and a secondport disposed on a surface of the first enclosure at or proximate to asecond end of the channel. The channel may have a length greater than ashortest distance between the first port and the second port, and thefirst port and the second port are in fluid communication. In somecases, the channel has a length greater than a length of the outerperimeter.

Some other method embodiments according to the disclosure includemethods for treating at least a portion of a subterranean formationpenetrated by a wellbore where a liquid component comprising water and asecond component comprising a hydratable polymer are introduced into atleast one hydration vessel, the mixture passed through the at least onehydration vessel in a continuous manner to form a slurry, a treatmentfluid then prepared which contains the slurry and an optional insolubleparticle, and the treatment fluid introduced into the wellbore. The atleast one hydration vessel includes an inlet chamber having a spiralingfirst fluid passageway, a discharge chamber having a spiraling secondfluid passageway, where the first fluid passageway and the second fluidpassageway are in fluid communication. In some cases, at least oneintermediate chamber is disposed between the inlet chamber and thedischarge chamber, where the intermediate chamber comprises a spiralingfirst intermediate fluid passageway, and the first fluid passageway, thesecond fluid passageway, and the first intermediate fluid passageway arein fluid communication.

Other method aspects of the disclosure relate to providing an apparatusincluding an inlet chamber having an outer perimeter and a first fluidpassageway formed therein, where the first fluid passageway has a lengthgreater than a shortest distance between the outer perimeter and centerof the inlet chamber, and the apparatus further includes a dischargechamber having an outer perimeter and a second fluid passageway formedtherein, where the second fluid passageway has a length greater than ashortest distance between the outer perimeter and center of thedischarge chamber. The first fluid passageway and the second fluidpassageway are in fluid communication. An admixture of a liquidcomponent containing a first chemical and a second component isintroduced into the apparatus, and flowed through the apparatus. Aproduct formed from the first chemical and the second component is thendischarged from the apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the disclosure will hereafter be described withreference to the accompanying drawings, wherein like reference numeralsdenote like elements. It should be understood, however, that theaccompanying figures illustrate the various implementations describedherein and are not meant to limit the scope of various technologiesdescribed herein, and:

FIG. 1 illustrates some apparatus embodiments in accordance with thedisclosure.

FIG. 2 depicts an exploded plan view of a hydration vessel in accordancewith the disclosure.

FIG. 3 shows a top plan view of an inlet chamber or enclosure inaccordance with the disclosure.

FIG. 4 depicts a bottom plan view of an inlet chamber or enclosure inaccordance with the disclosure.

FIG. 5 illustrates a top plan view of an intermediate chamber orenclosure in accordance with the disclosure.

FIG. 6 shows a bottom plan view of an intermediate chamber or enclosurein accordance with the disclosure.

FIG. 7 illustrates a top plan view of another intermediate chamber orenclosure in accordance with the disclosure.

FIG. 8 depicts a bottom plan view of another intermediate chamber orenclosure in accordance with the disclosure.

FIG. 9 illustrates a top plan view of a discharge chamber or enclosurein accordance with the disclosure.

FIG. 10 shows a bottom plan view of a discharge chamber or enclosure inaccordance with the disclosure.

FIG. 11 illustrates a system of enclosures, or chambers, which areconfigured and constructed as depicted in FIGS. 1 through 10, inaccordance with the disclosure.

FIGS. 12 and 13 depict an alternating inward/outward substantiallyspiral mixture flow pattern through an apparatus, without showing theapparatus in FIG. 12, and showing the apparatus in a transparentshadowed form in FIG. 13, in accordance with the disclosure.

FIGS. 14 and 15 show a top and bottom view of a rectangular chamber orenclosure, in accordance with the disclosure.

FIG. 16 depicts some embodiments of the disclosure where two hydrationvessel apparatus are fluidly connected in series, in accordance with thedisclosure.

FIG. 17 illustrates some further apparatus embodiments, in accordancewith the disclosure.

FIG. 18 depicts some further apparatus embodiments, in accordance withthe disclosure.

FIG. 19 illustrates a plate useful for affixing to outer ends ofchambers or enclosures, in accordance with the disclosure.

FIG. 20 shows a partition plate useful for affixing to chambers orenclosures, in accordance with the disclosure.

FIGS. 21 and 22 depict an outer chamber or enclosure in a top plan viewand an opposing bottom plan view, in accordance with the disclosure.

FIGS. 23 and 24 illustrate an intermediate chamber or enclosure in a topplan view and an opposing bottom plan view, in accordance with thedisclosure.

FIGS. 25 and 26 show another outer chamber or enclosure in a top planview and an opposing bottom plan view, in accordance with thedisclosure.

FIG. 27 illustrates, in an exploded view, a system of chambers orenclosures configured and constructed as depicted in FIGS. 18 through26, in accordance with the disclosure.

FIGS. 28 and 29 illustrate alternating inward/outward substantiallyspiral mixture flow pattern through a hydration vessel, without showingthe vessel in FIG. 28, and showing vessel in a transparent shadowed formin FIG. 29, in accordance with the disclosure.

FIG. 30 depicts some embodiments of the disclosure where two hydrationvessel apparatus are fluidly connected in series, in accordance with thedisclosure.

FIG. 31 illustrates another hydration vessel, or apparatus, inaccordance with the disclosure.

FIG. 32 shows the hydration vessel depicted in FIG. 31, in across-section format, in accordance with the disclosure.

FIG. 33 illustrates, in an interior view, the series of continuouschannels, or first fluid passageways, within the interior of hydrationvessel, in accordance with the disclosure.

FIG. 34 depicts an apparatus with enclosures shown in shadowed form,according to some aspects of the disclosure, to further illustrate howthe hydration concept of this disclosure would function in theembodiment described.

FIG. 35 illustrates, in cross-section view, a hydration vessel withnonparallel partitions, or plates, between channels or fluid passagewaysin nonparallel orientations, in accordance with the disclosure.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to providean understanding of some embodiments of the present disclosure. However,it will be understood by those of ordinary skill in the art that thesystem and/or methodology may be practiced without these details andthat numerous variations or modifications from the described embodimentsmay be possible.

Unless expressly stated to the contrary, “or” refers to an inclusive orand not to an exclusive or. For example, a condition A or B is satisfiedby anyone of the following: A is true (or present) and B is false (ornot present), A is false (or not present) and B is true (or present),and both A and B are true (or present).

In addition, use of the “a” or “an” are employed to describe elementsand components of the embodiments herein. This is done merely forconvenience and to give a general sense of the inventive concept. Thisdescription should be read to include one or at least one and thesingular also includes the plural unless otherwise stated.

The terminology and phraseology used herein is for descriptive purposesand should not be construed as limiting in scope. Language such as“including,” “comprising,” “having,” “containing,” or “involving,” andvariations thereof, is intended to be broad and encompass the subjectmatter listed thereafter, equivalents, and additional subject matter notrecited.

Finally, as used herein any references to “one embodiment” or “anembodiment” means that a particular element, feature, structure, orcharacteristic described in connection with the embodiment is includedin at least one embodiment. The appearances of the phrase “in oneembodiment” in various places in the specification are not necessarilyreferring to the same embodiment.

As used herein the term “enclosure” means a volume of space surroundedby outer surfaces of an apparatus, and is inclusive of such outersurfaces. The term “chamber” herein means a volume of space definedwithin outer surfaces of an apparatus. The term “channel” means asubstantially enclosed elongated opening within a chamber or enclosure.The term “passageway” means a continuing volume of space which connectsa first point to a second point within a chamber or enclosure. Thephrase “outer perimeter” means the distance around a two-dimensionalcross-sectional shape of a chamber or enclosure, and is not necessarilylimited to such a dimension measured on the exterior or the interior ofthe apparatus.

Some aspects of the disclosure relate to apparatus for, and methods of,forming a solvated mixture, or suspension, of a solids portion and aliquid medium by increasing residence time of the mixture within theapparatus. Some other aspects relate to apparatus for, and methods of,forming a product of a chemical contained in a liquid component and asecond component through increasing residence time of the admixturewithin the apparatus. Some other aspects relate to hydration ofhydratable material by increasing residence time of a mixture of waterand hydratable material within a hydration apparatus. The hydratablematerial may be a solid material, or other chemical, which is hydratablein an aqueous liquid, or even slurry of a hydratable material, which ismixed with the aqueous liquid portion. Some non-limiting examples ofhydratable material include viscosifying polymers, friction reducers,viscoelastic surfactants, cement components, drilling fluidconstituents, and the like. Some other aspects of the disclosure relateto apparatus and methods involving a flow of mixture of chemicalsundergoing a rate limited chemical process, or reaction, requiringresidence time with the help of a motive force such as gravity, pressureor a combination of both. The apparatus of the disclosure, as well asuse thereof, are useful in preparing a fluid from a mixture containingone or more materials which may react in any way, including association,such as surfactant, polymer or solids separation and association withwater in hydration, or even chemical reaction to form another materialthrough ionic or covalent bonding. As such, apparatus of the disclosuremay be referred to as hydration or reaction vessels. The apparatus andmethods may also be applied where a first-in/first-out (FIFO) process isused where different chemicals are introduced in sequence, and wheretime for a chemical reaction to complete, or substantially complete, isallowed before a second chemical is added to the flow.

Residence time within the apparatus may be improved, or extended, bydirecting the fluid mixtures through the apparatus via one or aplurality of chambers, or otherwise interior spaces, formed within anenclosure, or enclosures. In some aspects, the directing of the mixturemay be accomplished by passing the mixture through a continuous channelor passageway which has a length greater than a distance between theperimeter and center of a chamber, or even a length greater than theouter perimeter of the chamber, or interior space of the enclosure. Insome embodiments, the mixture is passed through a plurality ofsuccessive fluidly connected channels or passageways. The channel orpassageway, or plurality of channels or passageways, are fluidlyconnected with an inlet and outlet of the apparatus. A mixture may beintroduced into the apparatus, flow in a nonlinear pattern through theapparatus, and subsequently discharge in a greater hydrated, solvated orsuspended state. In some embodiments, channels or passageways aredisposed on opposing sides of a structure within the apparatus, whereeach side of the structure imparts turbulent flow characteristics intothe mixture as it passes through the channels or passageways, which mayin turn provide a reduction in requisite equipment volume to achievesuitable mixing or hydration. The figures and description only depicthow some embodiments may be enabled and function in a practical sensewithin the spirit of the concept of disclosure, and the concept is notsolely limited to the embodiments described.

In some embodiments of the disclosure, preparation of subterraneanformation treatment fluids, and more particularly, but not by way oflimitation, apparatus and methods for preparing a viscous gel fromessentially dry hydratable polymer constituents and water in acontinuous mode are described. In some cases, the apparatus and methodsare useful for preparing a viscous hydrated gel from dry polymer at awellbore site for fracturing a subterranean formation. Some embodimentsof the disclosure relate to first-in/first-out gel hydration vesselswhich provide effective polymer hydration by forcing a hydratablepolymer and fluid mixture to sweep a significant volume of a hydrationvessel. The volumetric capacity may be determined by the desired polymerconcentration, the required hydration time for the polymerconcentration, and the desired rate of hydrated polymer slurryproduction. In some aspects, the vessel design may be a pressure vesseldesign comprised of a series of flanged spiral-partitioned modularcomponents that are affixed with one another to form a staged assembly.In some embodiments, a pressurized polymer/fluid mixture may beintroduced into the vessel by a tangentially located inlet port on thevessel, and may flow in a spiral direction toward the center of thevessel within that stage, move to the next stage level and flow inspiral direction outwardly from the center, move to the next stage leveland flow in a spiral direction inward toward the center, and so on,until an at least partially, if not fully hydrated polymer slurry,emerges from an outlet. By enabling the mixture to flow in asubstantially spiral direction from stage to stage, pressure dropswithin the staged assembly due to flow direction reversal are minimized,thus allowing for more efficient power requirements to sustain themixture flow through the vessel. Additionally, in some embodiments, morethan one of these staged vessel assemblies may be connected to eachother in series to effectively increase the volume through which thepolymer/fluid mixture sweep through the vessels, in first-in/first-outfashion, to achieve the desired hydration for a given polymerconcentration, flow rate, and required hydration time.

As used herein: the term “gel” means any liquid material in a viscousstate suitable for any number of applications known in the art,including, but not limited to, treating a wellbore; “dry polymer”,“hydratable polymer”, “hydratable material” may mean, in some cases, anyform of polymer material which is commercially available, transferred,or supplied, in a solid, slurried and/or coated form (crystalline,amorphous, or otherwise), and not necessarily in an aqueous ornon-aqueous solution or slurry, and may be any polymer type useful forwell treatments, including, but not limited to, guar gums, which arehigh-molecular weight polysaccharides composed of mannose and galactosesugars, or guar derivatives such as hydroxypropyl guar (HPG),carboxymethyl guar (CMG), and carboxymethylhydroxypropyl guar (CMHPG).Cellulose derivatives such as hydroxyethylcellulose (HEC) orhydroxypropylcellulose (HPC) and carboxymethylhydroxyethylcellulose(CMHEC) may also be used. Any useful polymer may be used in eithercrosslinked form, or without crosslinker in linear form. Xanthan,diutan, and scleroglucan, three biopolymers, may also be useful aspolymers in accordance with the disclosure. Synthetic polymers such as,but not limited to, polyacrylamide and polyacrylate polymers andcopolymers, used typically for high-temperature and/or frictionreduction applications, may also be used. Also, associative polymers forwhich viscosity properties are enhanced by suitable surfactants andhydrophobically modified polymers can be used, such as cases where acharged polymer in the presence of a surfactant having a charge that isopposite to that of the charged polymer, the surfactant being capable offorming an ion-pair association with the polymer resulting in ahydrophobically modified polymer having a plurality of hydrophobicgroups, as described in published application U.S. 20040209780A1, Harriset. al. Any dry polymer may contain commercially acceptable moisturelevels, or have a coating or pre-treatment. The term “gel” may also meana slurry of partial or fully hydrated polymer in water. Hydratablematerial may also include other types of viscosifying agents, such asviscoelastic surfactants, or silicates, for example.

In some aspects of the disclosure, the liquid portion of a mixture maybe an aqueous medium which can include, for example, produced water,fresh water, seawater, brine or a combination thereof. In embodiments inwhich the aqueous medium includes brine, the brine can be, for example,water including an inorganic salt, organic salt or a combinationthereof. Suitable inorganic salts can include alkali metal halides suchas potassium chloride. The brine phase can include an organic salt suchas sodium or potassium formate, or sodium or potassium salicylate.Suitable inorganic divalent salts can include calcium halides such ascalcium chloride, calcium bromide or a combination thereof. Sodiumbromide, potassium bromide, or cesium bromide can be used, either aloneor in combination. The salt can be chosen for compatibility reasons.

Further, as used herein, the term “slurry” or “slurries” means any fluidmixture of the respective hydratable material with a liquid, which mayflow under low shear condition and is also capable of being pumped underpressure. Generally, to form the slurry, a mixture of the hydratablematerial and liquid are introduced into apparatus according to thedisclosure, subject to a suitable hydration residence time with theapparatus, and discharged from the apparatus where the hydratablematerial is at least partially hydrated. The unique interior designfeatures of the apparatus enable significantly improved hydrationeffectiveness compared to traditional hydration tanks with likevolumetric space.

Now referring generally to FIG. 1, which illustrates some apparatusembodiments according to the disclosure. FIG. 1 shows an apparatususeful for hydrating a mixture of water and a hydratable material, suchas hydratable polymers used to viscosify and/or reduce the turbulentflow properties of a subterranean formation treatment fluid. Apparatus100, which may be a vessel for at least partially hydrating, includes afirst enclosure 110 and may further include a second enclosure 120. Insome aspects of the disclosure, apparatus 100 may further include one ormore intermediate enclosures 130, 140 (eight shown). Apparatus 100 mayfurther include a port 112 disposed on the perimeter 114 of the firstenclosure 110. Port 112 may receive the mixture of water and ahydratable polymer, or any suitable mixture liquid and solid, forblending, or otherwise further mixing, to form a slurry. Port 122 mayalso be disposed on the perimeter 124 of the second enclosure 120 ofapparatus 100, and may produce, or otherwise discharge a slurry ofliquid and polymer, such as water and hydratable material, or anydesired mixture of materials in a liquid medium. Ports 112 and 122 maybe flush or extend outward from perimeters 114 and 124, and in someinstances, may extend outward in tangential direction relativeperimeters 114 and 124. In some aspects, the enclosures 110, 120, 130,and 140 are separate chambers, through which the mixture travels adistance over a time period for hydration. The enclosures, or chambers,are in fluid communication which allows the mixture to pass from port112, through first enclosure 110, then into any intermediateenclosure(s), then into second enclosure 120, and finally out of port122.

Apparatus 100 may further include first plate 150 (as shown in FIG. 2)which is affixed to first enclosure 110, which may serve to help confinethe mixture within the enclosure while passing through first enclosure110. First plate 150 may be affixed to enclosure 110 by any suitabletechnique, including removable fasteners attaching with a flange of theenclosure, welding, formed as an integrated portion of enclosure 110,and the like. Likewise, enclosures 110, 130 and 120 may affixed with oneanother by same or similar techniques. In FIG. 1, the enclosures showneach include a flange extending from the top and bottom perimeters (116and 118 for example), for receiving fasteners, such as nuts and bolts,and securing the enclosures (as well as plates where used) with oneanother.

Now referring to FIG. 2, which is an exploded plan view of vessel 200,according to some aspects of the disclosure. Enclosures 110, 120, 130and 140 include interior spaces 160, 170, 180 and 190 defined withineach enclosure. Within each interior space, at least one continuouschannel, or fluid passageway, may be disposed, or otherwise formed,therein. The continuous channel, or fluid passageway may be of lengthgreater than the length of the perimeter of the enclosure. For example,continuous channel 162 formed within the interior space 160 of enclosure110, has a length greater than perimeter 114. Referencing FIG. 3, inthose cases where the perimeter 114 is circular in shape, the length ofperimeter 114 is the circumference of enclosure 110, where thecircumference lies on a plane perpendicular to axial centerline 102.Similarly, in those instances where the shape of the perimeter is otherthan circular (i.e. rectangular, triangular, ovate, square, etc.), theperimeter length is the distance around the two-dimensional shape formedin a plane perpendicular to axial centerline.

As shown in FIG. 2, interior spaces 160, 170, 180 and 190 includecontinuous channels or passageways 162, 172, 182 and 192, respectively.The continuous channels are orientated and connected in such way toenable ports 112 and 122 to be in fluid communication. To illustrate,referring to FIGS. 3 and 4, in some embodiments, first port 112 disposedon perimeter 114 is in fluid communication with the first end 164 ofcontinuous channel 162, and another port 166 (shown in FIG. 4) isdisposed on a surface of enclosure 110 is in communication with a secondend 168 of continuous channel 162. FIG. 3 shows a top plan view, whileFIG. 4 shows an opposing bottom plan view. A fluid mixture may beintroduced into port 112, travel through continuous channel, or fluidpassageway, 162, and exit, or otherwise discharge, enclosure 110 at port166 positioned upon, or proximate, axial centerline 102. The mixture maythen flow into a next enclosure, such as enclosure 120 or enclosure 180,for example. In some embodiments, the mixture flows from port 166 intoenclosure 180, shown in FIG. 2.

Now referring to FIGS. 5 and 6, which show an intermediate enclosure, orchamber, in accordance with some aspects of the disclosure. FIGS. 5shows a top plan view, while FIG. 6 shows an opposing bottom plan view.Intermediate enclosure 130 includes continuous channel or passageway 182within interior space 180. The center of enclosure 130 is positioned onaxial centerline 102. A mixture may enter continuous channel 182 at ornear axial centerline 102, at end 188. The mixture may be supplied fromport 166 of enclosure 110, shown in FIG. 4, for example. Disposed on theopposing end 184 of channel 182 is port 186, which is positionedproximate perimeter 134. A mixture may exit enclosure 130 through port186, and flow into a next enclosure, such as enclosure 140 shown inFIGS. 1 and 2. Referencing FIGS. 7 and 8, which illustrate anotherintermediate enclosure, or chamber, in accordance with some aspects ofthe disclosure, in top plan view (FIG. 7) and opposing bottom plan view(FIG. 8). Intermediate enclosure 140 includes channel 192 withininterior spaces 190, and the center of enclosure 140 positioned on axialcenterline 102. The mixture may be introduced into channel 192 at ornear at end 194 proximate perimeter 144. The mixture may be suppliedfrom port 186 of enclosure 130, shown in FIG. 6. The mixture travelsthrough continuous channel 192, exits enclosure 140 through port 196,and flows into a next enclosure, such as enclosure 120 shown in FIGS. 1and 2. Alternatively, one or more pair of like enclosures 130 and 140could be disposed in similar fashion between enclosure 140 and enclosure120, such as the three additional pair shown in FIG. 1. While someillustrations show one pair of intermediate enclosures, or intermediatechambers, while others show four pair intermediate enclosures/chambers,it is within the spirit and scope of the disclosure to include anysuitable number of pairs of intermediate enclosures, or even no pair ofenclosures, between enclosures 110 and 120. Further, enclosures 110 and120 may also be considered inlet chambers and discharge chambers,respectively.

Referencing FIGS. 9 and 10, which illustrate second enclosure 120 in topand bottom plan views. Second enclosure 120 includes continuous channelor passageway 172 within interior space 170. The center of enclosure 120is positioned on axial centerline 102. A mixture may enter continuouschannel 172 at or near axial centerline 102, at end 178, and the mixturemay be supplied from port 196 of enclosure 140, shown in FIG. 8. Port122 is disposed on the opposing end 174 of channel 172 which ispositioned proximate perimeter 124. The mixture exits, or is otherwisedischarged, from the second enclosure 120 through port 122, in a fullyor partially slurried mixture of liquid and hydratable polymer, or evena product of an admixture in a liquid medium.

FIG. 11 illustrates a system of enclosures, or chambers, which areconfigured and constructed as depicted in FIGS. 1 through 10, anddescribed herein above. Apparatus, such as a hydration vessel, 300includes enclosures 110, 120, 130 and 140, as well as pairs ofintermediate enclosures 132, 134 and 136. Pairs of intermediateenclosures 132, 134 and 136, may be the same design as intermediateenclosures 130 and 140, in some aspects. Apparatus 300 further includesfirst plate 150 as part of enclosure 110, and ports 112 and 122. A fluidmixture may be introduced into the apparatus 112, travel through thesystem of continuous channels, or fluid passageways, of vessel 300, anddischarge through port 122. The mixture introduced into port 112 maytravel in a progressively inward direction toward the center ofenclosure 110, while moving substantially parallel with the perimeter ofenclosure 110. The mixture then transfers from enclosure 110 tointermediate enclosure 130, travels in a progressively outward directiontoward the perimeter of enclosure 130, while moving substantiallyparallel with the perimeter, until transferring to enclosure 140. Invessel 140, the mixture travels in a progressively inward directiontoward the center of enclosure 140, while moving substantially parallelwith the perimeter of enclosure 140. The mixture then transfers to, andtravels through each of the enclosures included in the pairs ofenclosures 132, 134 and 136, in successive order, moving through theenclosures in the same fashion as described for enclosures 130 and 140.The mixture then transfers from the last pair of enclosures 136, intoenclosure 120, travels in a progressively outward direction toward theperimeter of enclosure 120, while moving substantially parallel with theperimeter, until discharged through port 120. To summarize the order oftravel through the channels or passageways, the mixture travels firstthrough channel 162 in a progressively inward direction, then through182 in a progressively outward direction, channel 192 in a progressivelyinward direction, channel 183 in a progressively outward direction, thenchannel 193 in a progressively inward direction, channel 185 in aprogressively outward direction, then channel 195 in a progressivelyinward direction, then channel 187 in a progressively outward direction,channel 197 in a progressively inward direction, and then channel 172 ina progressively outward direction. The flow path of the mixturethroughout apparatus 300 is in alternating inward/outward substantiallyspiral patterns which is illustrated in FIG. 11. While spiral orsubstantially spiral flow patterns are illustrated in some embodimentsof the disclosure, any pattern of mixture flow which is movementsubstantially parallel with an enclosure perimeter while movingprogressively inward or progressively outward, is within the scope ofthe disclosure. Also, the terms ‘spiral’ and ‘substantially spiral’, asused in the disclosure are not solely limited to patterns within acircle, but may also mean patterns within ovate, square, rectangular,triangular, and the like, perimeter enclosures where directionalmovement is progressively inward or progressively outward, and thelength of the pattern, or otherwise pathway of movement, is at leastgreater than the distance formed between the center of the enclosure andgreatest distance from the center on the perimeter of the enclosure.Some spiral patterns useful in some enclosure embodiments, or over acombination of multiple enclosures, may be variable pitch and multiplepitch. Also, the spiral pattern may be single pitched, such as anarchimedean spiral, which is a plane curve generated by a point movingaway from or toward a fixed point at a constant rate while the radiusvector from the fixed point rotates at a constant rate.

In another aspect of the disclosure, vessels may have a singleenclosure, such as 110 depicted in FIGS. 3 and 4, with a port 112 influid communication with the first end 164 of channel 162, and anotherport 166 disposed on a surface of enclosure 110 in fluid communicationwith a second end 168 of continuous channel 162. A fluid mixture may beintroduced into port 112, travel through the channel, or fluidpassageway, 162, and exit 110 at port 166. While enclosure 110 is shownin FIG. 3 as open, a cover, such as 150 in FIG. 2, may be disposed overthe opening to seal the enclosure. The mixture may exit through port166, or even a pipe or conduit disposed upon the port.

Now referencing FIGS. 12 and 13, which together, illustrate analternating inward/outward substantially spiral mixture flow pattern 400through apparatus 300, without showing apparatus 300 in FIG. 12, andshowing apparatus 300 in a transparent shadowed form in FIG. 13. Inaccordance with the disclosure, the term ‘substantially spiral’, alsoreferred to as ‘spiral’ herein, means the pattern of flow is spiral innature, but may not be perfectly spiral due to enclosure design featuresand requirements, which would be readily apparent to those of skill inthe art, given the benefit of this disclosure. The mixture is introducedinto the inlet port 112 of chamber (or enclosure) 110 at point 402, thentravels in an inwardly spiral direction 406 before transferring to thenext chamber 130 at point 414. The mixture then moves outwardlyspiraling 416 before transferring to the next chamber 140 at point 424,then inwardly spiraling 426, transferring into chamber 132A at point434, outwardly spiraling 436, transferring to chamber 132B at 444, theninwardly spiraling 446, transferring into chamber 134A at point 454,then outwardly spiraling 456, transferring to chamber 134B at 464,inwardly spiraling 466, transferring into chamber 136A at point 474,outwardly spiraling 476, transferring to chamber 136B at 484, theninwardly spiraling 486, transferring to discharge chamber 120 at point494, outwardly spiraling 496, and then discharging from the chamber 120through discharge port 122 at point 404. As shown in FIG. 12, innertransfer points 414, 434, 454, 474 and 494 lie upon or proximate axialcenterline 102 of the apparatus. However, it will be appreciated thatthe inner transfer points may lie at any suitable position within achamber with the understanding that the inner transfer points are nearerthe axial centerline of the apparatus than the transfer pointspositioned nearer the perimeter, such as outer transfer points 424, 444,464 and 484. While it is shown in FIG. 12 example that first flowpath406 may spiral in a counterclockwise direction relative axial centerline102, and the next flowpath 416 may spiral in a counterclockwisedirection, and so on, the flowpaths may also be in a clockwisedirection. Also, it is within the scope of the disclosure that a firstflowpath is in a clockwise direction, the second in a counterclockwisedirection, and as applicable, subsequent directions alternating in thesame way. The inverse is also applicable, such as counterclockwisefirst, clockwise second, etc. Further, the flowpath need not be limitedto one direction, or alternate directions, and successive directions maybe inconsistent, such as, for example, clockwise, clockwise, thencounterclockwise, clockwise, counterclockwise, etc. Any suitablecombination of directions may be used in accordance with the disclosure,and the disclosure is not limited in any arrangement of flowpaths.

Referring now to FIGS. 14 and 15 which show a top and bottom view of achamber according to some aspects of the disclosure. Chamber 500 has asubstantially rectangular outer perimeter shape, in contrast to thecircular chambers, or enclosures, shown in FIGS. 1 through 11. Otherthan the general difference in outer perimeter shape, the features andfunction of the components described for the vessels and enclosuresillustrated in FIGS. 1 through 13 could be applied to a plurality ofsubstantially rectangular chambers 500. To illustrate, chamber 500 mayinclude a perimeter 514, and continuous channel, or fluid passageway,562 with a first end 564 and second end 568. Second end 568 may bedisposed upon or proximate axial centerline 102, while the first end 564disposed proximate perimeter 514. A port 566 may be disposed on surface540 of the chamber, and in fluid communication with a second end 568 ofcontinuous channel 562. In those cases where chamber 500 is located atthe inlet end of a hydration vessel, an inlet port may be disposed uponperimeter 514, proximate first end 564, at point 590, for example.Likewise, in instances where chamber 500 is located at the discharge endof a hydration vessel, a discharge port may be disposed upon perimeter514, at point 590, and proximate first end 564. However, when chamber500 is located at the discharge end, port 566 would not be disposed uponsurface 540, as a fluid mixture would be received at second end 568 froma similar chamber disposed above chamber 500. Fluid passageway 562 maybe of length greater than the length of the perimeter 514 of thechamber. The flow pattern of a mixture through fluid passageway 562 maysubstantially spiral in shape, or otherwise parallel with perimeter 514,in a plane perpendicular to centerline 102. While chamber 500 depicts asubstantially rectangular shape, chamber perimeter shapes which aretriangular, ovate, square, and the like, are within the scope of thedisclosure.

FIG. 16 depicts some embodiments of the disclosure where two hydrationvessel apparatus are fluidly connected in series. A plurality ofhydration vessels may be used to further increase swept volume capacityof a hydration vessel system. Hydration vessel system 600 includeshydration vessels 602 and 604 shown in transparent shadowed form, andfluid flowpaths 606 and 608 are shown therein. Vessels 602 and 604 mayinclude any of the features and function of the components described forthe vessels and enclosures illustrated in FIGS. 1 through 15. Forexample, hydration vessels 602 and 604 may be similar or like vessel300, with vessel 604 orientated in an inverted vertical orientation, orin other instances, orientated in the same manner with a suitableconduit connecting the vessels. A fluid mixture of water and hydratablepolymer may be introduced into system 600 at inlet port 610, and movethrough vessel 602 by flowpath 606. The mixture, which may be at leastpartially hydrated, exits vessel 602 at discharge port 612, then entersvessel 604 at inlet 614. The mixture moves through vessel 604 byflowpath 608, and exits vessel 604 at discharge port 616, produced as asubstantially hydrated slurry of hydratable material and water.

Now referencing FIG. 17, which illustrates some further apparatusembodiments according to the disclosure, such as a hydration vesseluseful for hydrating a mixture of water and a hydratable material, oreven forming a product from an admixture of components and chemicals.Apparatus 700 includes a first chamber 710 and a second chamber 720. Insome aspects of the disclosure, apparatus 700 may further include one ormore intermediate chambers as shown in FIG. 18. Apparatus 700 mayfurther include an inlet port 712 disposed on the perimeter 714 of firstchamber 710. Port 712 may receive the mixture of water and a hydratablematerial, or any suitable mixture liquid and solid, for blending, orotherwise further mixing, to form a slurry. Port 722 is disposed on theperimeter 724 of the second chamber 720 of apparatus 700, and mayproduce, or otherwise discharge a slurry of liquid and polymer, such aswater and hydratable material. Ports 712 and 722 may be flush or extendoutward from perimeters 714 and 724, and in some instances, may extendoutward in tangential direction relative perimeters 714 and 724. In someaspects, the chambers 710 and 720 are separate chambers, through whichthe mixture travels a distance over a time period for hydration. Thechambers, or enclosures, are in fluid communication which allows themixture to pass from port 712, through first chamber 710, then into anyintermediate chamber(s), then into second chamber 720, and finally outof port 722.

Apparatus 700 may further include a first plate 760 disposed on an outerend of first chamber 710, a second plate 762 (not shown) disposed on anouter end of second chamber 720, and a partition plate 770 (not shown)disposed between first chamber 710 and second chamber 720, which mayserve to help confine the mixture within the chambers 710 and 720.Plates 760, 762 and 770 may be affixed to the chambers by any suitabletechnique, including, but not limited to, removable fasteners attachingwith a flange of the enclosure, welding, formed as an integrated portionof the chamber, and the like. Similarly, chambers 710, 720, as well asany intermediate chambers, may be affixed with one another by same orsimilar techniques. In FIG. 17, the chambers shown each include a flangeextending from the top and bottom perimeters, for receiving fasteners,such as nuts and bolts, and securing the chambers (as well as plateswhere used) with one another.

Partition plate 770 further includes a port to establish fluidcommunication between inlet port 712 and discharge port 722. Within eachof first chamber 710 and second chamber 720 are disposed a first andsecond continuous channels (or fluid passageways), with an intermediatepartition plate separating the first and second continuous channels. Theintermediate partition plate includes a port to maintain fluidcommunication between the first and second continuous channels, as wellas fluid communication between inlet port 712 and discharge port 722.

Referring to FIG. 18, which depicts some further hydration vesselembodiments according to the disclosure. Similar to apparatus 700,hydration vessel 800 includes a first chamber 710 and a second chamber720. Hydration vessel 800 further includes at least one intermediatechamber, and in the illustration three are shown, 730, 740 and 750.Hydration vessel may further include an inlet port 712 disposed on theperimeter 714 of first chamber 710, for receiving a mixture of water anda hydratable material. Port 722 is disposed on the perimeter 724 of thesecond chamber 720, and may produce, or otherwise discharge a slurry. Asdescribed above, ports 712 and 722 may be flush with or extend outwardfrom perimeters 714 and 724, and in some instances, may extend outwardin tangential direction relative perimeters 714 and 724. Chambers 710,720, 730, 740 and 750 are in fluid communication which allows themixture to pass from inlet port 712 and out of discharge port 722.Partition plates 770, 772, 774 and 776 are disposed between respectivechambers 710 and 730, 730 and 740, 740 and 750, as well as 750 and 720.Partition plates 770, 772, 774 and 776 include a port to maintain fluidcommunication between inlet port 712 and discharge port 722. Similarwith chamber 710 and second chamber 720, chambers 730, 740 and 750 eachinclude first and second continuous channels, with an intermediatepartition plate separating the first and second continuous channels.Each intermediate partition plate includes a port to maintain fluidcommunication between the first and second continuous channels, as wellas fluid communication between inlet port 712 and discharge port 722.Hydration vessel also includes first plate 760 disposed upon an outerend of first chamber 710, and second plate 762 (not shown) disposed onan outer end of second chamber 720.

FIG. 19 illustrates a plate, which may be 760 or 762, useful foraffixing to outer ends of chambers 710 and 720. Plate 760 and 762 mayinclude holes 763 (twenty shown) disposed about the perimeter, in aflange bolt-hole pattern. FIG. 20 depicts a partition plate, which maybe 770, 772, 774 or 776, useful for helping maintain fluid communicationwithin hydration vessels 700 and 800, and affixed between chambers. Thepartition plate shown also includes holes 765 (twenty shown) disposedabout the perimeter, in a flange bolt-hole pattern. Partition plates770, 772, 774 and 776 further include port 767 proximate the outerperimeter of each plate.

Now turning to FIGS. 21 and 22, which illustrate first outer chamber 710depicted in FIGS. 17 and 18. FIG. 21 shows a top plan view, while FIG.22 shows an opposing bottom plan view. First port 712, which may be aninlet port, disposed on perimeter 714 is in fluid communication with thefirst end 764 of a continuous channel, or fluid passageway, 792.Continuous channel 792 is disposed within first chamber 710 in asubstantially spiral pattern, and includes second end 768 positioned ator near axial centerline 702. Continuous channel 792 is positioned uponintermediate partition plate 704. Intermediate partition plate 704 isdisposed within chamber 710, in a plane substantially perpendicular toaxial centerline 702, and further includes a port 766 (not shown)positioned at or near second end 768. As illustrated in FIG. 22, acontinuous channel 794 is disposed on an opposed surface of intermediatepartition plate 704. Continuous channel 794 includes first end 796disposed at or near axial centerline 702, and second end 798 positionedproximate perimeter 714. Continuous channel 794 has a substantiallyspiral pattern as well. Continuous channel 792 and continuous channel794 are in fluid communication by port 766. A mixture water andhydratable material may enter chamber 710 through port 712, pass throughcontinuous channel 792 in an inwardly spiraling manner, transfer tocontinuous channel 794 through port 766, travel through continuouschannel 794 in an outwardly spiraling pattern, and exit chamber 710 atend 798. In those cases where a partition plate with a port is disposedover continuous channel 794, such as partition plate 770 with a port 767(as shown in FIGS. 17, 18 and 20), the mixture may exit chamber 710through port 767 positioned at end 798, and then enter another chamber.

FIGS. 23 and 24 depict an intermediate chamber useful in someembodiments of the disclosure, and which describes intermediate chambers730, 740 and 750 shown in FIG. 18. FIG. 23 shows a top plan view, whileFIG. 24 shows an opposing bottom plan view. The intermediate chamberincludes a continuous channel, or fluid passageway, 802 disposed upon anintermediate partition plate 804. Continuous channel 802 includes afirst end 806 positioned proximate perimeter 814 of the intermediatechamber. Continuous channel 802 further includes a second end 808positioned at or near axial centerline 702, and intermediate partitionplate 804 includes a port 816 (not shown) positioned at or near secondend 808. Continuous channel 802 is disposed within the intermediatechamber in a substantially spiral pattern. As illustrated in FIG. 24, acontinuous channel 822 is disposed on an opposed surface of intermediatepartition plate 804. Continuous channel 822 includes first end 824disposed at or near axial centerline 702, and second end 826 positionedproximate perimeter 814. Continuous channel 822 has a substantiallyspiral pattern as well. Continuous channel 802 and continuous channel822 are in fluid communication by port 816. A mixture, such as water andhydratable material, may enter chamber 730, 740 or 750 at end 806 from aport, such as port 767 of partition plate 770, pass through continuouschannel 802 in an inwardly spiraling manner, transfer to continuouschannel 822 through port 816, travel through continuous channel 822 inan outwardly spiraling pattern, and exit chamber 730, 740 or 750 at end826. In instances where another partition plate with a port is disposedover continuous channel 822, such as partition plate 770 with a port 767(as shown in FIGS. 17, 18 and 20), the mixture may exit chamber 730, 740or 750 through port 767 positioned at end 826, and then enter anotherchamber. While FIG. 18 shows a hydration vessel including threeintermediate chambers 730, 740 and 750, and FIG. 17 depicts a vesselwith no intermediate chamber, these example are not limiting, and it iswithin the spirit and scope of the disclosure to include any suitablenumber of intermediate chambers.

Referencing FIGS. 25 and 26, which show second outer chamber 720depicted in FIGS. 17 and 18. FIG. 25 depicts a top plan view, while FIG.26 shows an opposing bottom plan view. Continuous channel, or fluidpassageway, 852 is disposed within second chamber 720 in a substantiallyspiral pattern, and positioned upon an intermediate partition plate 854.Continuous channel 852 includes a first end 856 positioned proximateperimeter 724 of chamber 720, and a second end 858 positioned at or nearaxial centerline 702. Intermediate partition plate 854 includes a port866 (not shown) positioned at or near second end 858. Now turning toFIG. 26, a continuous channel 874 is disposed on an opposed surface ofintermediate partition plate 854. Continuous channel 874 includes afirst end 876 disposed at or near axial centerline 702, and second end878 positioned proximate perimeter 714. Disposed on the perimeter ofchamber 720 and at the second end 878 is discharge port 722. Continuouschannel 874 has a substantially spiral pattern as well. Continuouschannel 852 and continuous channel 874 are in fluid communicationthrough port 866. A mixture of water and hydratable material may enterchamber 720 at first end 856 from a port disposed above, pass throughcontinuous channel 852 in an inwardly spiraling flowpath, transfer tocontinuous channel 874 through port 866, travel through continuouschannel 874 in an outwardly spiraling manner to second end 878, and exitchamber 720 at discharge port 722.

FIG. 27 illustrates, in an exploded view, the system of enclosures, orchambers, which are configured and constructed as depicted in FIGS. 18through 26, and described herein above. Hydration vessel, 800 includeschambers 710, 720, 730, 740 and 750, each with a pair of alternatingspiraling continuous channels disposed therein. The center of chambers710, 720, 730, 740 and 750 are positioned upon axial centerline 702.Each chamber includes intermediate partition plates within as well, theintermediate partition plates each including a port disposed at or nearaxial centerline 702. Partition plates 770, 772, 774 and 776 arepositioned between the respective chambers, and further include ports767 proximate the outer perimeter of each plate. Plate 760 is disposedupon an outer end of first chamber 710, and plate 762 disposed on anouter end of second chamber 720. A liquid/polymer mixture may beintroduced into inlet port 712, passing through the plurality ofchambers through the series of substantially spiraling continuouschannels and ports, then exit at discharge port 722 in the form of an atleast partially hydrated slurry.

While chambers 710, 720, 730, 740 and 750 are depicted circularperimeter shapes, other perimeter shapes such as rectangular,triangular, ovate, square, and the like, are within the scope of thedisclosure. Further, while the flow pattern of the continuous channelsare described as substantially spiral in FIGS. 17 through 26, thecontinuous channels, or fluid passageways, are essentially of lengthgreater than the length of the perimeter of its respective chamber. Thenumber of rotations of a spiral pattern is not necessarily limiting forembodiments of the disclosure, as long as the continuous channels, areessentially of length greater than perimeter length.

In yet another aspect of the disclosure, vessels may have a singleenclosure, such as 710 depicted in FIGS. 21 and 22, with port 712 influid communication with the first end 764 of channel 792. Channel 792is disposed within first chamber 710 and includes second end 768, andpartition plate 704 disposed within chamber 710, and further includes aport 766 positioned at or near second end 768. FIG. 22 shows channel 794disposed on an opposed surface of intermediate partition plate 704, andchannel 794 includes first end 796 disposed at or near axial centerline702, and second end 798 positioned proximate perimeter 714. Disposed onthe perimeter of chamber 710 and at the second end 798 may be adischarge port, such as 722 shown in FIGS. 25 and 26. While enclosure710 is shown in FIGS. 21 and 22 as open, covers such as 760 shown inFIG. 19, may be disposed over the openings to seal the enclosure.

FIGS. 28 and 29 illustrate alternating inward/outward substantiallyspiral mixture flow pattern 1000 through hydration vessel 800, withoutshowing vessel 800 in FIG. 28, and showing vessel 800 in a transparentshadowed form in FIG. 29. Flow pattern 1000 is illustrated to provide ageneral depiction of material flow through hydration vessel like orsimilar to the vessel 800, and may be applicable to any variations invessel design utilizing chambers with intermediate partition plates andpartition plates, such as those described above. The mixture isintroduced into the inlet port 712 of outer chamber (or enclosure) 710at point 1002, then travels through a first continuous channel in aninwardly spiral direction 1006 before transferring, at or near axialcenterline 702, to a second continuous channel of chamber 710 at point1014. The mixture then moves outwardly spiraling 1016 beforetransferring to the next chamber 730 at point 1024. The mixture thentravels through a first continuous channel of chamber 730 in an inwardlyspiral direction 1026 before transferring to a second continuous channelof chamber 730 at point 1034, and then moves through the secondcontinuous channel of chamber 730 in an outwardly spiraling pattern 1036to then transfer to the next chamber 740 at point 1044. The mixture thenenters a first continuous channel of chamber 740 and travels in aninwardly spiraling fashion 1046 to point 1054, and transfers to a secondcontinuous channel of chamber 740. In the second continuous channel ofchamber 740, the mixture moves in an outwardly spiraling pattern 1056 topoint 1064, and moves to chamber 750. Upon entering chamber 750, themixture moves in an inwardly spiral direction 1066 through a firstcontinuous channel, then transfers at point 1074 into a secondcontinuous channel and travels in an outwardly spiral direction 1076 topoint 1084. The mixture then transfers to a first continuous channel inouter chamber 720 and moves in an inwardly spiraling direction 1086through a first continuous channel, to point 1094. At point 1094, themixture transfers to a second continuous channel in outer chamber 720,travels in an outwardly spiraling pattern 1096, and then discharges fromouter chamber 720 at point 1004.

FIG. 30 depicts some embodiments of the disclosure where two hydrationvessel apparatus, such as vessels 800, are fluidly connected in series.The plurality of hydration vessels may be used to further increase sweptvolume capacity of a hydration vessel system. Hydration vessel system900 includes hydration vessels 902 and 904 shown in transparent shadowedform, and fluid flowpaths 906 and 908 are shown therein. Vessels 902 and904 may include any of the features and function of the componentsdescribed for the vessels and enclosures illustrated in FIGS. 17 through29. For example, hydration vessels 902 and 904 may be similar or likevessel 800, with vessel 904 orientated in a like vertical orientation asvessel 902 with a suitable conduit connecting the vessels, or in otherinstances, orientated in an inverted manner. A fluid mixture of waterand hydratable material may be introduced into system 900 at inlet port910, and move through vessel 902 by flowpath 906. The mixture, which maybe at least partially hydrated in some cases, exits vessel 902 atdischarge port 912, then enters vessel 904 at inlet 914. The mixturemoves through vessel 904 by flowpath 908, and exits vessel 904 atdischarge port 916, produced as a substantially hydrated slurry ofhydratable material and water.

Referring now to FIG. 31, which illustrates another hydration vessel, orapparatus, according to the disclosure. The hydration vessel 1200includes first enclosure 1204 having an interior space defined therein,and second enclosure 1206 having an interior space defined therein,where enclosures 1204 and 1206 may be affixed with one another atflanges 1208 and 1210. In some aspects of the disclosure, the interiorspace defined within an outer portion 1216 of first enclosure 1204 maybe considered an inlet chamber, while the interior space defined withinan outer portion 1218 of second enclosure 1206 may be considered adischarge chamber. First enclosure 1204 further includes an inlet port1212 disposed on the surface, which may be useful for receiving amixture of hydratable material and water. A discharge port 1214 (shownin FIG. 32) is disposed on a surface of the second enclosure 1206, andmay be utilized to produce a slurry of water and at least partiallyhydrated material.

FIG. 32 shows the hydration vessel 1200 in a cross-section format, wherethe cross-section is made at plane 1-1 parallel to and lying upon axialcenterline 1202 of vessel 1200 depicted in FIG. 31. The interior spacedefined within outer portion 1216 of first enclosure 1204 includes afirst continuous channel, or first fluid passageway, 1218 having achannel-length greater than a length of the outer perimeter of the firstenclosure 1204. In the embodiment illustrated, a mixture may beintroduced through inlet port 1212 (shown in FIG. 31) and travel in aprogressively inward pattern through first continuous channel 1218 toport 1222 disposed at, or proximate axial centerline 1202. In somealternative embodiments, the mixture may be introduced through an inletport disposed in other suitable locations on the surface of firstenclosure 1204 and travel through first continuous channel, or firstfluid passageway, 1218 in a progressively outward pattern. Referringagain to the embodiment depicted in FIG. 32, the mixture may passthrough a series of additional continuous channels, or fluidpassageways, within the hydration vessel 1200, as described in furtherdetail below, and then enter into second continuous channel, or secondfluid passageway, 1220, through port 1224 (shown in FIG. 33). Port 1224may be disposed at, or proximate, the perimeter of outer portion 1218 ofsecond enclosure 1206. The mixture may then travel in a progressivelyinward pattern through second continuous channel 1220 and discharge as apartially or substantially fully hydrated slurry of water and hydratablematerial through discharge port 1214. While discharge port 1214 isdepicted as disposed at, or proximate to, the axial centerline 1202 ofouter portion 1218 of second enclosure 1206, in some alternativeembodiments, the mixture may travel through second continuous channel1218 in a progressively outward pattern, and discharge through a portdisposed at any suitable location on second enclosure 1206. Inlet port1212 and discharge port 1214 of hydration vessel 1200 are in fluidcommunication.

Now referencing FIG. 33 which illustrates in an interior view, theseries of continuous channels, or first fluid passageways, within theinterior of hydration vessel 1200, as well as referencing FIG. 32. Theseries of continuous channels, or first fluid passageways, are in fluidcommunication with one another, as well as inlet port 1212 and dischargeport 1214, of hydration vessel 1200. The mixture described above, isintroduced into first continuous channel 1218 at point 1226, and travelsin a progressively inward pattern, substantially parallel to theperimeter of enclosure, or chamber, 1204, to point 1228. At point 1228,the mixture exits continuous channel 1218 at port 1222 (shown in FIG.32), and enters third continuous channel, or fluid passageway 1230. Themixture may then travel in a progressively outward pattern, andsubstantially parallel to the above described perimeter, to point 1232.At point 1232, a fourth port is disposed at or proximate an end of thirdcontinuous channel, or fluid passageway, 1230 where the mixture thenenters fourth continuous channel, or fluid passageway 1234. The mixturetravels in a progressively inward pattern to port 1236, and enters fifthcontinuous channel, or fluid passageway 1238. Travelling in aprogressively outward pattern, the mixture reaches point 1240, andtransfers to a sixth continuous channel, or fluid passageway, 1242,through a port. The mixture then travels in a progressively inwardpattern, and exits channel 1242 at port 1244. After entering seventhcontinuous channel, or fluid passageway, 1246, the mixture continues ina progressively outward pattern through channel 1246 to point 1248. Atpoint 1248, the mixture transfers to second continuous channel, or fluidpassageway, 1220, through port 1224, then travels in a progressivelyinward pattern, substantially parallel with the perimeter, and isdischarged through port 1214.

FIG. 34 depicts apparatus 1200, with enclosures shown in shadowed form,according to some aspects of the disclosure, to further illustrate howthe hydration concept of this disclosure would function in theembodiment described. Mixtures described above would enter hydrationvessel 1200 though inlet port 1212, spiral through first channel 1218,transfer to and spiral through third channel 1230, transfer to andspiral through fourth channel 1234, transfer to and spiral through fifthchannel 1238, transfer to and spiral through sixth channel 1242,transfer to and spiral through sixth channel 1246, transfer to andspiral through second channel 1220, and discharge from port 1214 (shownin FIG. 32). While FIGS. 31 through 34 illustrate one apparatus, orhydration vessel, 1200, a plurality of such apparatus be may connectedin series, parallel, or combination of series and parallel, is withinthe scope and spirit of the disclosure.

FIG. 35 illustrates another aspect of the disclosure, in cross-sectionview, which is a hydration vessel with nonparallel partitions, orplates, between continuous channels or fluid passageways, in nonparallelorientations. The cross-section is made on plane parallel to and lyingupon axial centerline 1252, otherwise the vessel is substantiallycylindrical in an overall three dimensional shape. Hydration vessel 1250includes a first enclosure 1254 and second enclosure 1256. A mixture maybe introduced into hydration vessel 1250 at point 1258 and move in aninwardly spirally pattern through fluid passageway 1260, which isdisposed upon partition plate 1262. As shown, partition plate 1262 liesin a plane substantially perpendicular to axial centerline 1252. Thevertical dashed lines shown in the illustration represent the wallstructures which form the vertical limits of the fluid passageways, thepassageways are fluidly continuous from the inner perimeter to thecenter of the hydration vessel, and the passageways are substantiallyspiral in shape. Hence, the fluid passageways have a length greater thanthe perimeter of the hydration vessel.

At point 1264, the mixture transfers through a port to fluid passageway1266, which is disposed between partition plates 1262 and 1268. Asshown, partition plate 1268 is not orientated parallel with plate 1262.The mixture passes in an outwardly spiral pattern through fluidpassageway 1266 to point 1270, and transfers through a port to fluidpassageway 1272. Fluid passageway 1272 is disposed between partitionplates 1268 and 1274, and the plates are not orientated in parallelplanes. The mixture then moves in an inwardly spiral through fluidpassageway 1272 to point 1276, and passes through a port, near or ataxial centerline 1252, to fluid passageway 1278. Fluid passageway 1278is disposed between partition plates 1274 and 1280, the plates notorientated in parallel planes. The mixture then passes in an outwardlyspiral pattern through fluid passageway 1278 to point 1282, andtransfers through a port to fluid passageway 1284. Fluid passageway 1284is disposed between partition plates 1280 and 1286, the plates notorientated in parallel planes. The mixture then moves in an inwardlyspiral pattern through fluid passageway 1284 to point 1288, and passesthrough a port to fluid passageway 1290. Fluid passageway 1290 isdisposed between partition plates 1286 and 1292, and planes 1286 and1292 are not orientated in planes perpendicular with axial centerline1252. The mixture then passes in an outwardly spiral pattern throughfluid passageway 1290 to point 1294, and moves through a port into fluidpassageway 1296. The mixture then travels in an inwardly spiral patternthrough fluid passageway 1296 to point 1298, enters a discharge outlet1300, and exits hydration vessel 1250 at point 1302, produced as slurryof partially or substantially hydrated material and water. While theembodiment illustrated in FIG. 35 shows an arrangement of a plurality ofpartition plates orientated in different planes, and other figuresillustrate partition plates orientated in similar planes, theillustrations are merely examples, and the disclosure is not limited tothose plate orientations described and shown. It will be appreciatedthat any suitable orientation is within the scope of the disclosure.

Some embodiments shown in the illustrations and described above depictpartition plates, or surfaces, which substantially separate a continuouschannel, or fluid passageway, from another continuous channel, or fluidpassageway, while allowing the channels or passageways to be in fluidcommunication with each other, as well as an inlet and outlet of theapparatus. While plates are shown, other structures which would enablethe same balance of separation and adequate fluid communication may beutilized, such as baffles, or any other structure which serves as aflow-directing vane or panel. Further, while continuous channels orpassageways are depicted as connected by ports, continuous channelscould also be in the form of augers, a series of augers, or any othersuitable structure which enable the mixture to be hydrated, suspended,or dissolved by traveling through the apparatus in a distance greaterthan the length of the perimeter of the apparatus.

Further, while the foregoing examples and figures describe continuouschannels or fluid passageways which are formed within the chambers orinterior of the enclosures with a continuous wall or partitionconfiguration, embodiments of the disclosure are not limited to onlysuch designs, and it is well within the scope of the disclosure to havesuch channels or passageways constructed by any suitable design, such aspipe, conduit, square tubular, and the like. Additionally, components ofthe apparatus described may be constructed of any suitable material orcombinations thereof, including, but not limited to metal, plastic,composites, etc. Further, while it is general shown that apparatus ofthe disclosure include a port for receiving a mixture, and a port fordischarging a slurry, mixture or product, some alternative embodimentsmay include ports on the periphery of the apparatus for variouspurposes, including, sampling, monitoring, controlling, injecting othermaterials into the mixture during movement through the apparatus, andthe like.

Also within the scope of the disclosure are methods for treating atleast a portion of a subterranean formation penetrated by a wellbore,which include introducing into one or more reaction vessels (such asthose vessels and apparatus described herein) a mixture of a liquidcomponent containing a first chemical reactant, and a second chemicalreactant, and the mixture is passed through the at least one reactionvessel. A treatment fluid is then prepared and contains the mixture andan optional insoluble particle, and subsequently introduced into awellbore. The reaction vessel has a first enclosure having an outerperimeter and an interior space defined therein, a channel disposed inthe interior space, a first port disposed on a surface of the firstenclosure at or proximate to a first end of the channel, and a secondport disposed on a surface of the first enclosure at or proximate to asecond end of the channel. The channel may have a length greater than ashortest distance between the first port and the second port, and thefirst port and the second port are in fluid communication. In somecases, the channel has a length greater than a length of the outerperimeter, and the channel has an archimedian spiral pattern. Thereaction vessel, as well as any vessels and apparatus according to thedisclosure, may further include at least one static mixing elementwithin the channel, an axial mixer within the vessel, or combination ofboth. The mixture produced in the vessel may be injected into a highpressure fluid stream, and in some instances, the mixture injected is apill comprising a high concentration of the second chemical reactant.

The second chemical reactant may be a water hydratable material, orotherwise water reactable material, and the liquid component may beaqueous based including water as a first chemical reactant. The mixturemay undergo a rate limited chemical reaction requiring residence time,while flowing the mixture through the reaction vessel under theinfluence of gravity, pressure or combination thereof. The concentrationof water reactable material may be any suitable concentration,including, but not limited to about 25 pounds per 1000 gallons of liquidcomponent or greater, about 30 pounds per 1000 gallons of liquidcomponent or great, about 40 pounds per 1000 gallons of liquid componentor greater, or even about 50 pounds per 1000 gallons of liquid componentor greater.

The method may further include decreasing the concentration of the firstchemical reactant, the second chemical reactant, or both, during thecourse of the treatment. Such a decrease in concentration may enableimproved flushing and cleaning of the vessel and overall system. In someaspects, pressure change of the mixture is measured across the at leastone reaction vessel to monitor a reaction of the first chemical reactantwith the second chemical reactant. Also, the mixture may be passedthrough a plurality of such reaction vessels.

Some methods may further include use of a second enclosure having anouter perimeter and an interior space defined therein, where the secondenclosure has a second channel disposed in the interior space, a thirdport disposed on a surface of the second enclosure at or proximate to afirst end of the second channel, and a fourth port disposed on a surfaceof the second enclosure at or proximate to a second end of the secondchannel. The second port, the third port and fourth port are in fluidcommunication. The channel of the first enclosure and the second channelmay have an archimedian spiral pattern, where a first fluid flowpath isin a progressively inward direction through the channel of the firstenclosure, and a second fluid flowpath is in a progressively outwarddirection through the second channel, or alternatively, a first fluidflowpath is in a progressively outward direction through the channel ofthe first enclosure, and a second fluid flowpath is in a progressivelyinward direction through the second channel. Such a change in directionof fluid flowpaths may impart energy into the mixture to furtheroptimize the reaction of the two materials.

In yet other methods, a plurality of enclosures is used, or any suitablenumber thereof, where each of the enclosures has an outer perimeter andan interior space defined therein, a channel disposed in the interiorspace, a port disposed on a surface of the enclosure at or proximate toa first end of the channel, and a port disposed on a surface of theenclosure at or proximate to a second end of the channel, and whereinthe channel has a length greater than a shortest distance between theports, and wherein the second port and the ports disposed on the surfaceof the plurality of enclosures are in fluid communication. One or moreadditional chemical components are injected into the plurality ofreaction vessels at one or more points downstream from the first port.

Some other method embodiments according to the disclosure includemethods for treating at least a portion of a subterranean formationpenetrated by a wellbore where a liquid component including water and asecond component having a hydratable polymer are introduced into atleast one hydration vessel, the mixture passed through the at least onehydration vessel in a continuous manner to form a slurry, a treatmentfluid then prepared which contains the slurry and an optional insolubleparticle, and the treatment fluid introduced into the wellbore. Thehydration vessel includes an inlet chamber having a spiraling firstfluid passageway, and a discharge chamber having a spiraling secondfluid passageway, where the first fluid passageway and the second fluidpassageway are in fluid communication. A first fluid flowpath may beorientated in a progressively inward direction through the first fluidpassageway, and a second fluid flowpath in a progressively inwarddirection through the second fluid passageway. The alternative may bethe case as well, where the first fluid flowpath may be orientated in aprogressively outward direction, and the second fluid flowpath in aprogressively outward direction. The hydration vessel may furtherinclude an inlet port disposed on a perimeter of the inlet chamber, anda discharge port disposed on a perimeter of the discharge chamber. Somemethod embodiments also involve utilizing a plurality of hydrationvessels connected in a series configuration, a parallel configuration,or combination thereof.

In some of the methods, the hydration vessel may further include atleast one intermediate chamber disposed between the inlet chamber andthe discharge chamber, where the at least one intermediate chambercomprises a spiraling first intermediate fluid passageway, and the firstfluid passageway, the second fluid passageway, and the firstintermediate fluid passageway are in fluid communication. In some cases,the at least one intermediate chamber is at least one pair ofintermediate chambers disposed between the inlet chamber and thedischarge chamber, the pair of intermediate chambers including a firstintermediate chamber having a spiraling first intermediate fluidpassageway, and a second intermediate chamber having a spiraling secondintermediate fluid passageway, where the first fluid passageway, thesecond fluid passageway, the first intermediate fluid passageway and thesecond intermediate fluid passageway are in fluid communication. Asecond pair of intermediate chambers may further be disposed between theat least one pair of intermediate chambers and the discharge chamber, athird pair of intermediate chambers disposed between the second pair ofintermediate chambers and the discharge chamber, a fourth pair ofintermediate chambers disposed between the third pair of intermediatechambers and the discharge chamber, and so on. Any practical number ofintermediate chambers, or pairs thereof, are within the scope and spiritof the disclosure.

In some aspects, at least one intermediate chamber is disposed betweenthe inlet chamber and the discharge chamber, where the intermediatechamber comprises a spiraling first intermediate fluid passageway, andthe first fluid passageway, the second fluid passageway, and the firstintermediate fluid passageway are in fluid communication. Optionally,the at least one intermediate chamber is at least one pair ofintermediate chambers disposed between the inlet chamber and thedischarge chamber, and have a first intermediate chamber comprising aspiraling first intermediate fluid passageway, and a second intermediatechamber comprising a spiraling second intermediate fluid passageway,where the first fluid passageway, the second fluid passageway, the firstintermediate fluid passageway and the second intermediate fluidpassageway are in fluid communication. The at least one intermediatechamber may include a first and a second fluid passageway, where thefluid passageways are partitioned by a plate having a hole therein, andwhere the first and the second fluid passageways are in fluidcommunication. Also, the first outer chamber and the second outerchamber may each have a first and a second fluid passageway, where thefluid passageways are partitioned by a plate having a hole therein, andwhere the first and the second fluid passageway are in fluidcommunication.

Yet other method aspects of the disclosure relate to preparing a productfrom an admixture of a first chemical contained in a liquid component,and a second component. The first chemical may be the same as the liquidcomponent in some cases, while in other cases, a chemical suspended ordissolved in the liquid component. The admixture mixture includes one ormore materials that may react in any way, such as polymer, surfactant orsolids separation and association with water in hydration, or evenchemical reaction to form another material through ionic or covalentbonding. The admixture is introduced into an apparatus including aninlet chamber (such as 110 of FIG. 1, referenced as one example) havingan outer perimeter 114 and a first fluid passageway 162 formed therein,where the first fluid passageway has a length greater than a shortestdistance between the outer perimeter and center of the inlet chamber.The admixture may be introduced into the first fluid passageway througha port, such as 112 or 162, flowed through the first fluid passageway,to then exit and then enter a discharge, or otherwise second chamber ofthe apparatus, through another port. The discharge chamber includes anouter perimeter and a second fluid passageway formed therein, and thesecond fluid passageway has a length greater than a shortest distancebetween the outer perimeter and center of the discharge chamber. Thefirst fluid passageway and the second fluid passageway are in fluidcommunication. The admixture is flowed through the apparatus anddischarged from the apparatus as a product formed from the firstchemical and the second component. The direction of admixture flowthrough the first fluid passageway and the second fluid passageway maybe in opposite directions in some aspects, different directions in otheraspects, or even in like directions. Ports may be disposed at anypractical position upon and/or within the combination of chambers. Thechambers may be formed within separate enclosures, or formed within asingle enclosure. The apparatus may also include additional chambers aswell.

Apparatus and methods of the disclosure may be useful in subterraneanformation treatments where continuous mixing and hydration of wellviscous treatment gels from dry polymer are required at a wellbore site,whether land based or offshore. However, the processes and apparatus mayhowever be used for mixing other types of powder material with liquidsas well. At a wellbore site once the well has been drilled andconstructed and the drill rig removed, the site may be prepared forsubterranean formation treatment or stimulation. The surface, or rigfacilities and layout typically involve a number of pieces of mobileequipment including fracture fluid storage tanks, sand storage units,chemical trucks, blending equipment and pumping equipment. All facets ofthe hydraulic fracturing job from the blending and pumping of thefracture fluids and proppants—solid material, usually sand or othersolid material, that is pumped into fractures to hold them open—to theway the rock formation responds to the fracturing, are often managedfrom a single control location. Apparatus of the disclosure may be acomponent of the blending equipment, and in fluid communication withpumping equipment. Integration of the apparatus and methods into theformation treatment equipment set up will be readily apparent to thoseof skill in the art having the benefit of this disclosure.

Lastly, in accordance with the disclosure, the hydratable polymer may bepresent at any suitable concentration in the mixture or produced slurry.In various embodiments hereof, the hydratable polymer can be present inan amount of from about 0.1 wt. % to about 10 wt. % of total weight ofthe mixture, from about 0.1 wt. % to about 7 wt. % of total weight ofthe mixture, from about 0.1 wt. % to about 5 wt. % of total weight ofthe mixture, from about 0.1 wt. % to about 4 wt. % of total weight ofthe mixture, from about 0.1 wt. % to about 3 wt. % total weight of themixture, from about 0.1 wt. % to about 2 wt. % of total weight of themixture, or even from about 0.1 wt. % to about 1 wt. % of total weightof the mixture. Slurries incorporating the hydratable polymer may haveany suitable viscosity, and in some instances a viscosity value of about50 mPa-s or greater at a shear rate of about 100 s⁻¹ at treatmenttemperature, or about 75 mPa-s or greater at a shear rate of about100^(s−1), or even about 100 mPa-s or greater at a shear rate of about100^(s−1).

The foregoing description of the embodiments has been provided forpurposes of illustration and description. Example embodiments areprovided so that this disclosure will be thorough, and will fully conveythe scope to those who are skilled in the art. Numerous specific detailsare set forth such as examples of specific components, devices, andmethods, to provide a thorough understanding of embodiments of thedisclosure, but are not intended to be exhaustive or to limit thedisclosure. Individual elements or features of a particular embodimentare generally not limited to that particular embodiment, but, whereapplicable, are interchangeable and can be used in a selectedembodiment, even if not specifically shown or described. The same mayalso be varied in many ways. Such variations are not to be regarded as adeparture from the disclosure, and all such modifications are intendedto be included within the scope of the disclosure.

It will be apparent to those skilled in the art that specific detailsneed not be employed, that example embodiments may be embodied in manydifferent forms and that neither should be construed to limit the scopeof the disclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail. Further, it will be readily apparent to those ofskill in the art that in the design, manufacture, and operation ofapparatus to achieve that described in the disclosure, variations inapparatus design, construction, condition, erosion of components, gapsbetween components may present, for example.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

Although various embodiments have been described with respect toenabling disclosures, it is to be understood the invention is notlimited to the disclosed embodiments. Variations and modifications thatwould occur to one of skill in the art upon reading the specificationare also within the scope of the invention, which is defined in theappended claims.

What is claimed is:
 1. A method for treating at least a portion of asubterranean formation penetrated by a wellbore, the method comprising:a) introducing into at least one reaction vessel a mixture comprising:i) a liquid component comprising a first chemical reactant; ii) a secondchemical reactant; b) passing the mixture through the at least onereaction vessel; c) preparing a treatment fluid which comprises themixture and an optional insoluble particle; and d) introducing thetreatment fluid into the wellbore; wherein the reaction vesselcomprises: a) a first enclosure having an outer perimeter and aninterior space defined therein; b) a channel disposed in the interiorspace; c) a first port disposed on a surface of the first enclosure ator proximate to a first end of the channel; and, d) a second portdisposed on a surface of the first enclosure at or proximate to a secondend of the channel; wherein the channel has a length greater than ashortest distance between the first port and the second port, andwherein the first port and the second port are in fluid communication.2. The method of claim 1 wherein the first chemical reactant is waterand the second chemical reactant is a water reactable material.
 3. Themethod of claim 1 wherein the channel has a length greater than a lengthof the outer perimeter.
 4. The method of claim 1 further comprising asecond enclosure having an outer perimeter and an interior space definedtherein, the second enclosure comprising a second channel disposed inthe interior space, a third port disposed on a surface of the secondenclosure at or proximate to a first end of the second channel, and afourth port disposed on a surface of the second enclosure at orproximate to a second end of the second channel, wherein the secondport, the third port and fourth port are in fluid communication.
 5. Themethod of claim 1 further comprising a plurality of enclosures, whereineach of the plurality of enclosures comprise an outer perimeter and aninterior space defined therein, a channel disposed in the interiorspace, a port disposed on a surface of the enclosure at or proximate toa first end of the channel, and a port disposed on a surface of theenclosure at or proximate to a second end of the channel, and whereinthe channel has a length greater than a shortest distance between theports, and wherein the second port and the ports disposed on the surfaceof the plurality of enclosures are in fluid communication.
 6. The methodof claim 1 wherein the mixture undergoes a rate limited chemicalreaction requiring residence time, while flowing the mixture through thereaction vessel under the influence gravity, pressure or combinationthereof.
 7. The method of claim 2 wherein the concentration of waterreactable material is greater than or equal to about 40 pounds per 1000gallons of liquid component.
 8. The method of claim 1 wherein themixture is passed through a plurality of reaction vessels.
 9. The methodof claim 8 wherein one or more additional chemical components areinjected into the plurality of reaction vessels at one or more pointsdownstream from the first port.
 10. The method of claim 1 wherein thereaction vessel further comprises at least one static mixing element, anaxial mixer, or combination thereof.
 11. The method of claim 1 furthercomprising measuring pressure change of the mixture across the at leastone reaction vessel to monitor a reaction of the first chemical reactantwith the second chemical reactant.
 12. The method of claim 1 decreasingthe concentration of the first chemical reactant, the second chemicalreactant, or both, during the treating.
 13. The method of claim 1wherein the channel has an archimedian spiral pattern.
 14. The method ofclaim 13 wherein the mixture is injected into a high pressure fluidstream.
 15. The method of claim 14 wherein the mixture injected into ahigh pressure fluid stream is a pill comprising a high concentration ofthe second chemical reactant.
 16. The method of claim 4 wherein thechannel and the second channel have an archimedian spiral pattern, andwherein a first fluid flowpath is in a progressively inward directionthrough the channel of the first enclosure, and wherein a second fluidflowpath is in a progressively outward direction through the secondchannel.
 17. The method of claim 4 wherein the channel and the secondchannel have an archimedian spiral pattern, and wherein a first fluidflowpath is in a progressively outward direction through the channel ofthe first enclosure, and wherein a second fluid flowpath is in aprogressively inward direction through the second channel.
 18. A methodfor treating at least a portion of a subterranean formation penetratedby a wellbore, the method comprising: a) introducing into at least onehydration vessel a mixture comprising: i) a liquid component comprisingwater; ii) a second component comprising a hydratable material; b)passing the mixture through the at least one hydration vessel in acontinuous manner to form a slurry; c) preparing a treatment fluid whichcomprises the slurry and an optional insoluble particle; and d)introducing the treatment fluid into the wellbore; wherein the hydrationvessel comprises: a) an inlet chamber comprising a spiraling first fluidpassageway; and, b) a discharge chamber comprising a spiraling secondfluid passageway; wherein the first fluid passageway and the secondfluid passageway are in fluid communication.
 19. The method of claim 18further comprising at least one intermediate chamber disposed betweenthe inlet chamber and the discharge chamber, wherein the at least oneintermediate chamber comprises a spiraling first intermediate fluidpassageway, wherein the first fluid passageway, the second fluidpassageway, and the first intermediate fluid passageway are in fluidcommunication.
 20. The method of claim 19 wherein the at least oneintermediate chamber is at least one pair of intermediate chambersdisposed between the inlet chamber and the discharge chamber, the pairof intermediate chambers comprising: i) a first intermediate chambercomprising a spiraling first intermediate fluid passageway; and, ii) asecond intermediate chamber comprising a spiraling second intermediatefluid passageway; wherein the first fluid passageway, the second fluidpassageway, the first intermediate fluid passageway and the secondintermediate fluid passageway are in fluid communication.
 21. The methodof claim 19 wherein the at least one intermediate chamber comprises afirst and a second fluid passageway, wherein the fluid passageways arepartitioned by a plate having a hole therein, and wherein the first andthe second fluid passageways are in fluid communication.
 22. The methodof claim 19 wherein the first outer chamber and the second outer chambereach comprise a first and a second fluid passageway, wherein the fluidpassageways are partitioned by a plate having a hole therein, andwherein the first and the second fluid passageway are in fluidcommunication.
 23. The method of claim 22 wherein a first fluid flowpathis in a progressively inward direction through the first fluidpassageway, and wherein a second fluid flowpath is in a progressivelyoutward direction through the second fluid passageway.
 24. The method ofclaim 19 wherein a first fluid flowpath is in a progressively inwarddirection through the first fluid passageway, and wherein a second fluidflowpath is in a progressively inward direction through the second fluidpassageway.
 25. The method of claim 18 wherein the hydration vesselfurther comprises an inlet port disposed on a perimeter of the inletchamber, and a discharge port disposed on a perimeter of the dischargechamber.
 26. The method of claim 19 wherein the hydration vessel furthercomprises a second pair of intermediate chambers disposed between the atleast one pair of intermediate chambers and the discharge chamber. 27.The method of claim 26 wherein the hydration vessel further comprises athird pair of intermediate chambers disposed between the second pair ofintermediate chambers and the discharge chamber.
 28. The method of claim27 wherein the hydration vessel further comprises a fourth pair ofintermediate chambers disposed between the third pair of intermediatechambers and the discharge chamber.
 29. The method of claim 20 whereinthe inlet chamber, the at least one intermediate chamber, and thedischarge chamber are substantially circular or ovate in outer perimetershape.
 30. The method of claim 20 wherein the inlet chamber, the atleast one intermediate chamber, and the discharge chamber aresubstantially rectangular in outer perimeter shape.
 31. The method ofclaim 19 wherein the hydration vessel further comprises at least onepair of intermediate chambers disposed between the first intermediatechamber and the discharge chamber, the pair of intermediate chamberscomprising: i) a second intermediate chamber comprising a spiralingsecond intermediate fluid passageway; and, ii) a third intermediatechamber comprising a spiraling third intermediate fluid passageway;wherein the first fluid passageway, the second fluid passageway, thefirst intermediate fluid passageway, the second intermediate fluidpassageway and the third intermediate passageway are in fluidcommunication.
 32. The method of claim 31 wherein the hydration vesselfurther comprises a second pair of intermediate chambers disposedbetween the at least one pair of intermediate chambers and the dischargechamber.
 33. The method of claim 32 wherein the hydration vessel furthercomprises a third pair of intermediate chambers disposed between thesecond pair of intermediate chambers and the discharge chamber.
 34. Themethod of claim 33 wherein the hydration vessel further comprises afourth pair of intermediate chambers disposed between the third pair ofintermediate chambers and the discharge chamber.
 35. The method of claim18 wherein the at least one hydration vessel is a plurality of hydrationvessels connected in a series configuration.
 36. The method of claim 18wherein the at least one hydration vessel is a plurality of hydrationvessels connected in a parallel configuration.
 37. A method comprising:a) providing an apparatus, the apparatus comprising: i. an inlet chamberhaving an outer perimeter and a first fluid passageway formed therein,wherein the first fluid passageway has a length greater than a shortestdistance between the outer perimeter and center of the inlet chamber;and, ii. a discharge chamber having an outer perimeter and a secondfluid passageway formed therein, wherein the second fluid passageway hasa length greater than a shortest distance between the outer perimeterand center of the discharge chamber; wherein the first fluid passagewayand the second fluid passageway are in fluid communication; b)introducing into the apparatus, an admixture comprising: i) a liquidcomponent comprising a first chemical; and, ii) a second component; c)flowing the admixture through the apparatus; and, d) discharging fromthe apparatus a product formed from the first chemical and the secondcomponent.